Panel assemblies and methods to assemble the same

Abstract

A panel assembly can include a first panel having a peripheral side located between an upper and a lower surface of the first panel and a first opening. The panel assembly can also include a second panel having a second opening. An elongated insert can be coupled to the first panel, the elongated insert having a coupling side, where the first opening of the first panel can be sized and shaped to coupleably receive the elongated insert such that the coupling side is positioned proximal to the peripheral side. The panel assembly can also include a fastening insert, where the second opening of the second panel can be sized and shaped to receive the fastening insert. A fastener can be received by the fastening insert and the elongated insert, the fastener coupling the first panel to the second panel via the fastening insert and the elongated insert. Related methods for assembling the panel assembly are also provided.

The invention claimed is: 
     
       1. An elongated insert capable of coupling panels of an aircraft panel assembly, the elongated insert comprising:
 a top side; 
 a single web extending downwardly from the top side and extending to at least one peripheral edge of the top side, the single web including a pair of solid, cylindrical bosses that protrude outwardly therefrom; and 
 a coupling side that is arranged to be positioned adjacent to a proximal side of one of the panels of the aircraft panel assembly. 
 
     
     
       2. The elongated insert of  claim 1  wherein a first one of the pair of solid cylindrical bosses protrudes outwardly from the single web in a first direction and a second one of the pair of solid cylindrical bosses protrudes outwardly from the single web in a second direction, the second direction being opposite of the first direction. 
     
     
       3. The elongated insert of  claim 1  wherein the top side includes a pair of apertures that extend therethrough, the apertures sized and shaped to allow potting compound to flow around a main body of the elongated insert. 
     
     
       4. The elongated insert of  claim 1  wherein the coupling side includes an aperture that partially extends through the coupling side, the aperture sized and shaped to coupleably receive a fastener that is sized and shaped to couple the panels of the aircraft panel assembly. 
     
     
       5. The elongated insert of  claim 1 , further comprising:
 a bottom side having a surface area, wherein a surface area of the top side is larger than a surface area of the bottom side. 
 
     
     
       6. The elongated insert of  claim 1 , further comprising:
 one or more recesses which define a flow region around a main body of the elongated insert. 
 
     
     
       7. The elongated insert of  claim 1 , further comprising:
 flow regions around a main body of the elongated insert that are sized and shaped to receive potting compound which flows around the elongated insert, a flow of the potting compound around the main body coupling the elongated insert to one of the panels. 
 
     
     
       8. An elongated insert configured to be received in a panel of an aircraft panel assembly, the elongated insert comprising:
 a top side, the top side having a first surface area; 
 a bottom side, the bottom side having a second surface area, the second surface area being less than the first surface area; 
 a coupling side; and 
 a web spanning the top side and the bottom side, the web extending to peripheral edges of the top side and the bottom side. 
 
     
     
       9. The elongated insert of  claim 8  wherein the web includes a pair of solid, cylindrical bosses that protrude outwardly therefrom. 
     
     
       10. The elongated insert of  claim 9  wherein a first one of the pair of solid cylindrical bosses protrudes outwardly from the web in a first direction and a second one of the pair of solid cylindrical bosses protrudes outwardly from the web in a second direction, the second direction being opposite of the first direction. 
     
     
       11. A fastening insert capable of coupling panels of an aircraft panel assembly, the fastening insert comprising
 a cap portion having a lower surface and a fastener aperture; 
 a shaft portion having a threaded insert aperture, the fastener aperture and the threaded insert aperture defining a fastener receiving aperture which is sized and shaped to coupleably receive a fastener that is configured to couple the panels together via the fastening insert; and 
 one or more gussets that extends between an outer surface of the shaft portion and the lower surface of the cap portion. 
 
     
     
       12. The fastening insert of  claim 11 , further comprising:
 one or more bosses protruding outwardly from the lower surface. 
 
     
     
       13. The fastening insert of  claim 11  wherein the threaded insert aperture is sized and shaped to receive a threaded insert which receives the fastener that couples the panels together. 
     
     
       14. The fastening insert of  claim 11  wherein the fastener receiving aperture is located at an offset relative to a central axis of the fastening insert. 
     
     
       15. The fastening insert of  claim 11  wherein the cap portion includes a pair of openings disposed around a periphery of the cap portion, the pair of openings sized and shaped to receive a potting compound which flows one of the panels to bond the fastening insert received in one of the panels of the aircraft panel assembly.